A GUIDE TO THE USE OF ELECTRICAL EQUIPMENT IN POTENTIALLY EXPLOSIVE ATMOSPHERES

Introduction
Potentially Explosive Atmospheres exist where there is a risk of explosion due to mixtures of gas/air, vapour/air, dust/air or other flammable combinations. In such areas there is a necessity to eliminate sources of ignition such as sparks, hot surfaces or static electricity which may ignite these mixtures. Where electrical equipment has to be used in these areas it must be so designed and constructed as to not create sources of ignition capable of igniting these mixtures. Before electrical equipment can be used in a potentially explosive atmosphere a representative sample has to be fully tested and certified by an independent authority such as Baseefa 2001 in Europe or UL in the U.S.A. This information is intended as a guide only and further expert guidance should be sought before placing into service, maintaining or repairing any item of equipment in a Potentially Explosive Atmosphere. Where comparisons are shown between, for example, European and North American practice this may be an approximation and individual standards/codes of practice should be consulted for precise details. MEDC have spent 25 years designing and manufacturing electrical equipment suitable for use in potentially explosive atmospheres. We deal with all the major testing and certification authorities throughout the world and have a diverse range of internationally approved products.

Area Classification
Process plants are divided into Zones (European and IEC method) or Divisions (North American method) according to the likelihood of a potentially explosive atmosphere being present. Note : North American legislation now allows Zones to be used to classify areas, where this practice is used it follows the IEC Zone method. European & IEC Classification Zone 0 (gases) Zone 20 (dusts) Zone 1 (gases) Zone 21 (dusts) Zone 2 (gases) Zone 22 (dusts) Definition of zone or division An area in which an explosive mixture is continuously present or present for long periods An area in which an explosive mixture is likely to occur in normal operation An area in which an explosive mixture is not likely to occur in normal operation and if it occurs it will exist only for a short time North American Classification Class I Division 1 (gases) Class II Division 1 (dusts) Class I Division 1 (gases) Class II Division 1 (dusts) Class I Division 2 (gases) Class II Division 2 (dusts) Class III Division 1 (fibres) Class III Division 2 (fibres)

Gas Groups (plus dusts and fibres)

There are two main gas groups, Group I Mining only and Group II Surface Industries These categories are used in European and I.E.C. groupings. Group I is concerned only with underground mining where methane and coal dust are present. Group II gases occurring in surface industries, are sub-grouped according to their volatility. This enables electrical equipment to be designed to less onerous tolerances if it is to be used with the least volatile gases. Typical gas/material Methane Acetylene Hydrogen Ethylene Propane Metal dust Coal dust Grain dust European/I.E.C. Gas Group I IIC IIC IIB IIA North American Gas Group A B C D E F G

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6DS101/H

Temperature
Hot surfaces can ignite explosive atmospheres. To guard against, this all Electrical Equipment intended for use in a potentially explosive atmosphere is classified according to the maximum surface temperature it will reach in service. This temperature is normally based on a surrounding ambient temperature of 40 degrees Centigrade (102 degrees Fahrenheit). This temperature can then be compared to the ignition temperature of the gas(es) which may come into contact with the equipment and a judgement reached as to the suitability of the equipment to be used in that area. Many MEDC products are certified for use in ambient temperatures up to 55 degrees Centigrade, see individual data sheets for details. Temperature Classification European/I.E.C. North American T1 T1 T2 T2 T2A T2B T2C T2D T3 T3A T3B T3C T4 T4A T5 T6 Maximum Surface Temperature 450 C 300 C 280 C 260 C 230 C 215 C 200 C 180 C 165 C 160 C 135 C 120 C 100 C 85 C

T3

T4 T5 T6

e.g. Butane has an ignition temperature of 365 degrees Centigrade, equipment used in the vicinity of this gas would need a T rating of T2 or higher.

Types of Electrical Equipment Suitable for use in Potentially Explosive Atmospheres

Different techniques are used to prevent electrical equipment from igniting explosive atmospheres. There are restrictions on where these different types of equipment can be used as follows : European Area of use Designation Standard Flameproof Enclosure An enclosure used to house electrical equipment, which when subjected to an internal explosion will not ignite a surrounding explosive atmosphere. Intrinsic Safety A technique whereby electrical energy is limited such that any sparks or heat generated by electrical equipment is sufficiently low as to not ignite an explosive atmosphere. Increased Safety This equipment is so designed as to eliminate sparks and hot surfaces capable of igniting an explosive atmosphere. Purged and Pressurised Electrical equipment is housed in an enclosure which is initially purged to remove any explosive mixture, then pressurisedto prevent ingress of the surrounding atmosphere prior to energisation. Encapsulation A method of exclusion of the explosive atmosphere by fully encapsulating the electrical components in an approved material. Oil Immersion The electrical components are immersed in oil, thus excluding the explosive atmosphere from any sparks or hot surfaces. Powder Filling Equipment is surrounded with a fine powder, such as quartz, which does not allow the surrounding atmosphere to come into contact with any sparks or hot surfaces. Non-sparking Sparking contacts are sealed against ingress of the surrounding atmosphere, hot surfaces are eliminated. Zones 1 & 2 Exd EN60079-1 Zones 0, 1 & 2 Exi EN60079-11 Zones 1 & 2 Exe EN60079-7 Zones 1 & 2 Exp EN60079-2 Zones 1 & 2 Exm EN60079-18 Zone 1 & 2 EExo EN50015 Zones 1 & 2 EExq EN50017 Zone 2 Exn EN60079-15 IEC Area of use Designation Standard Zones 1 & 2 Exd IEC60079-1 Zones 1 & 2 Exi IEC60079-11 Zones 1 & 2 Exe IEC60079-7 Zones 1 & 2 Exp IEC60079-2 Zone 1 & 2 Exm IEC60079-18 Zones 1 & 2 Exo IEC60079-6 Zones 1 & 2 Exq IEC60079-5 Zone 2 Exn IEC60079-15 USA Area of use Designation Standard Class I Divisions 1 & 2 UL1203 Class I Divisions 1 & 2 UL913 Class I Divisions 1 & 2 NFPA496 Class I Division 2 UL698

Selection, Installation and Maintenance of Electrical Equipment Intended for use in Potentially Explosive Atmospheres
International and national standards are published giving details of requirements for the safe use of Electrical Equipment in Potentially Explosive Atmospheres as follows : International General Recommendations Classification of Hazardous Areas Inspection and Maintenance of Electrical Equipment Requirements for Flameproof Enclosures Requirements for Intrinsically Safe Equipment Requirements for Increased Safety Equipment Requirements for Purged and Pressurised Equipment Requirements for Non-Sparking Equipment IEC60079-14 IEC60079-10 IEC60079-17 IEC60079-14 IEC60079-14 IEC60079-14 IEC60079-14 IEC60079-14 Europe EN60079-14 EN60079-10 EN60079-17 EN60079-14 EN60079-14 EN60079-14 EN60079-14 EN60079-14 U.S.A. N.E.C. Chapter 5 N.E.C. Chapter 5 N.E.C. Chapter 5 N.E.C. Chapter 5 N.E.C. Chapter 5 N.E.C. Chapter 5 -

MEDC advise that all Explosion-proof electrical equipment is maintained, by suitably trained personnel, in accordance with the Manufacturers recommendations. Any spare parts used should be purchased from the original Manufacturer and repairs should be carried out by the Manufacturer or under his supervision, in order that the item remains in conformance with the certification documents.

The Certification Process

All Electrical Equipment, intended for use in a Potentially Explosive Atmosphere, should be certified as suitable for such use. The methods of obtaining certification differ in detail, see below, between each certifying body or group of bodies (e.g. CENELEC). Basically this process consists of supplying a representative sample of the equipment along with a set of drawings to a recognised test/certification body e.g. Baseefa 2001 who in turn test the equipment against a recognised Standard e.g. EN60079-14 and issue a Certificate. The user of the equipment can then refer to this Certificate to enable him to safely put the item into service in a zone appropriate to the Certification. European Practice ALL EQUIPMENT, BOTH ELECTRICAL AND MECHANICAL, INTENDED TO BE PUT INTO SERVICE WITHIN THE EEC HAS TO BE CERTIFIED IN ACCORDANCE WITH THE ATEX DIRECTIVE. It should be noted also that MECHANICAL equipment is covered by the ATEX Directive so for the first time items such as gearboxes will have to carry ATEX certification. The equipment coding signifying compliance with ATEX is as follows: II2G i.e. Explosionproof in accordance with ATEX. II Group II surface industries. 2 category 2 equipment (suitable for use in Zone 1) note: Category 1 is suitable for Zone 0. Category 3 is suitable for Zone 2.

G suitable for atmospheres containing gas (D is suitable for atmospheres containing dusts). Equipment will be CE marked when certified to ATEX.

North American practice Sample equipment and supporting documentation are submitted to the appropriate authority e.g.U.L., F.M., C.S.A. The equipment is tested in accordance with relevant standards for explosion protection and also for general electrical requirements e.g. light fittings. After successful testing a listing is issued allowing the manufacturer to place the product on the market. The product is marked with the certification details such as the gas groups A,B,C,D the area of use e.g. Class 1 Division 1.

Worldwide Certification
Most countries outside Europe or North America use the IEC Standards as a basis for their own national standards. The Russian Federation certifies equipment to GOST R standards, these closely follow CENELEC practice. In Russia, certain products used in fire alarm systems may be required to carry the Russian fire approval (VNIIPO). Note that not all MEDC products that have been certified to GOST R are VNIIPO approved. Check specification on technical data sheets before ordering. Kazakhstan has a certification process (GOST K) where approval is normally based on compliance with CENELEC standards. Certification in China is based on compliance with international standards such as CENELEC or UL.

There is a scheme in place which will when fully adopted allow for internationally recognised certification to become a reality, this is the IEC EX SCHEME. This uses the IEC standards and IEC recognised test and certification bodies to issue mutually recognised test reports and certificates. The scheme is in its infancy and its level of success cannot yet be measured.

Ingress Protection
2 digits are used to denote the level of ingress protection that a piece of apparatus enjoys:
0 1 2 3 4 5 6

IP
Solids No protection. Protected against solid objects up to 50mm, e.g. hands. Protected against solid objects up to 12mm, e.g. fingers. Protected against solid objects up to 2.5mm, e.g. tools. Protected against solid objects over 1mm, e.g. wires. Protected against dusts. (No harmful deposits). Totally protected against dust. 0 1 2 3 4 5 6 7 8 No protection. Protected against vertically falling drops of water. Protected against water spray up to 15 degrees from vertical. Protected against water spray up to 60 degrees from vertical. Protected against water sprays from all directions. Protected against water jets from all directions. Protected against strong water jets from all directions, e.g. Offshore. Protected against immersion between 15cm and 1m in depth. Protected against long immersion under pressure. Liquids

North American practice is to use NEMA standards to describe ingress protection, i.e.: NEMA NEMA NEMA NEMA 3 4 4x 6 is is is is similar similar similar similar to to to to IP IP IP IP 54 55 56 67

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